Modules for Manufacturing Systems and Modular Manufacturing Systems

ABSTRACT

The present disclosure is directed, in part, to a method of transporting rolls of a fibrous material. The method comprises providing a V-shaped conveying mechanism, stacking a plurality of the rolls of the fibrous material on the V-shaped conveying mechanism, and transporting the plurality of the rolls of the fibrous material between a first position and a second position.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/497,114, filed on Jun. 15, 2011, the entiredisclosure of which is fully incorporated by reference herein.

FIELD

The present disclosure generally relates to methods of processing rollsof materials and, more particularly, relates to methods of processingrolls of fibrous materials.

BACKGROUND

Current manufacturing systems and equipment for the same have manylimitations. In some instances, it is difficult and/or costly toreconfigure these systems and equipment for manufacturing a differentproduct or for adding a new component or feature to an existing productbecause of the lack of flexibility within existing manufacturing systemsand equipment. Furthermore, it is sometimes difficult to change ormodify packaging methods and/or packaging configurations for variousproducts using existing manufacturing systems and equipment againbecause of their lack of flexibility or their lack of easy change-out orchange-over features. To alleviate these issues, some manufacturingsystems have attempted to use modules in manufacturing systems. Invarious technical disciplines, however, the existing modules: (1) maynot be truly modular (e.g., equipment extends from one module intoanother adjacent module), (2) may not be adaptable for a plurality ofmanufacturing steps or processes (i.e., the module may only be able tobe used for one specific manufacturing step or process), (3) may only beconfigurable to manufacture a limited number of products, (4) mayrequire a great deal of time and effort to change-over the module toperform a different step or process, and/or (5) may need to be replacedcompletely, or completely restructured, to produce different products,different product features, and/or different product arrangements. Whatis needed are methods of processing rolls of fibrous materials thatovercome the issues identified above.

SUMMARY

In one form, the present disclosure is directed, in part, to a method ofprocessing rolls of fibrous materials. The method comprises providing amodule comprising an internal adjustment mechanism, attaching a firstpiece of equipment to the module to enable the module to perform a firstfunction, and adjusting the module for the first piece of equipmentusing the internal adjustment mechanism of the module. The methodfurther comprises removing the first piece of equipment from the module,attaching a second piece of equipment to the module to enable the moduleto perform a second function, and adjusting the module for the secondpiece of equipment using the internal adjustment mechanism of themodule. The first piece of equipment is different than the second pieceof equipment and the first function is different than the secondfunction.

In another form, the present disclosure is directed, in part, to amethod of processing rolls of fibrous materials. The method comprisesproviding a first module and a second module. Each of the modulescomprises an internal adjustment mechanism. The method further comprisesattaching a first piece of equipment to the first module and adjustingthe first piece of equipment using the internal adjustment mechanism ofthe first module and independent of any adjustment mechanisms on thefirst piece of equipment. The method further comprises attaching asecond piece of equipment to the second module and adjusting the secondpiece of equipment using the internal adjustment mechanism of the secondmodule and independent of any adjustment mechanisms on the second pieceof equipment. The first piece of equipment is different than the secondpiece of equipment and the first module is positioned upstream of thesecond module.

In still another form, the present disclosure is directed, in part, to amethod of transporting rolls of a fibrous material. The method comprisesproviding a V-shaped conveying mechanism, stacking a plurality of therolls of the fibrous material on the V-shaped conveying mechanism, andtransporting the plurality of the rolls of the fibrous material betweena first position and a second position.

In yet another form, the present disclosure is directed, in part, to amodule for a modular manufacturing system. The module comprises a frameand a carriage movable relative to the frame. The movement of thecarriage is in directions generally perpendicular to the direction ofproduct flow through the module. The carriage comprises a basecomprising a first equipment mount movably engaged with the base and asecond equipment mount movably engaged with the base. The first and thesecond equipment mounts are moveable relative to each other indirections generally perpendicular to the direction of product flowthrough the module and generally perpendicular to the directions ofmovement of the carriage.

In still another form, the present disclosure is directed, in part, to amodule for a modular manufacturing system. The module comprises a frameand a first carriage comprising a first portion and a second, separateportion. The first portion or the second, separate portion isindependently movable relative to the other portion and relative to theframe. The module further comprises a second carriage comprising a firstportion and a second portion. The first portion of the first carriagecomprises a first base comprising a first equipment mount. The secondportion of the first carriage comprises a second base comprising asecond equipment mount. The first portion or the second portion of thesecond carriage comprises a base engaged with a conveyor.

In yet another form, the present disclosure is directed, in part, to amodular manufacturing system. The modular manufacturing system comprisesa first module comprising a first piece of equipment and a second modulecomprising a second piece of equipment. The second module is positionedadjacent to the first module. A gap is defined intermediate the firstmodule and the second module. No equipment extends into the gap fromeither of the first module or the second module. The first and secondmodules each comprise a first carriage, a second carriage, and anadjustment mechanism operably coupled to the first carriage or thesecond carriage. The adjustment mechanism is configured to move thefirst carriage or the second carriage relative to the other carriage.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a module for a modular manufacturingsystem in accordance with one non-limiting embodiment;

FIG. 2 is another perspective view of the module of FIG. 1 in accordancewith one non-limiting embodiment;

FIG. 3 is a side view of the module of FIG. 1 in accordance with onenon-limiting embodiment;

FIG. 4 is a front view of the module of FIG. 1 in accordance with onenon-limiting embodiment;

FIG. 5 is a perspective view of a module for a modular manufacturingsystem in accordance with one non-limiting embodiment;

FIG. 6 is a top view of a first carriage for a module of a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 7 is a bottom view of the first carriage of FIG. 6 in accordancewith one non-limiting embodiment;

FIG. 7A is a top view of an equipment mount in accordance with onenon-limiting embodiment;

FIG. 7B is a top view of an additional equipment mount positionedintermediate a first equipment mount and a second equipment mount inaccordance with one non-limiting embodiment;

FIG. 8 is a top view of a second carriage for a module of a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 9 is a bottom view of the second carriage of FIG. 8 in accordancewith one non-limiting embodiment;

FIG. 10 is a cut away side view a module for a modular manufacturingsystem in accordance with one non-limiting embodiment;

FIG. 11 is a front view of a module for a modular manufacturing systemin accordance with one non-limiting embodiment;

FIG. 12 is a top view of a first carriage for a module of a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 13 is a bottom view of the first carriage of FIG. 12 in accordancewith one non-limiting embodiment;

FIG. 14 is a perspective view of a frame for a module of a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 15 is a perspective view of another frame for a module of a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 16 is a perspective view of a module for a modular manufacturingsystem using the frame of FIG. 15 in accordance with one non-limitingembodiment;

FIG. 17 is a perspective view of the module of FIG. 16 with variouscomponents removed for illustration in accordance with one non-limitingembodiment;

FIGS. 18-20 are front views of modules with various components removedfor illustration in accordance with various non-limiting embodiments;

FIG. 21 is a perspective view of another module for a modularmanufacturing system in accordance with one non-limiting embodiment;

FIG. 22 is a perspective view of the module of FIG. 21 with variouscomponents removed in accordance with one non-limiting embodiment;

FIG. 23 is a front view of a module for a modular manufacturing systemwith various components removed for illustration in accordance with onenon-limiting embodiment;

FIGS. 24-26 are front views of modules for modular manufacturing systemsillustrating various numbers and sizes of products within a processwindow in accordance with various non-limiting embodiments;

FIG. 27 is a block diagram of an example modular manufacturing system inaccordance with one non-limiting embodiment; and

FIG. 28 is an example modular manufacturing system comprising a returnconveyor in accordance with one non-limiting embodiment.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the methods of processingrolls of fibrous materials disclosed herein. One or more examples ofthese non-limiting embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that themethods of processing rolls of fibrous materials described herein andillustrated in the accompanying drawings are non-limiting exampleembodiments and that the scope of the various non-limiting embodimentsof the present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting embodimentcan be combined with the features of other non-limiting embodiments.Such modifications and variations are intended to be included within thescope of the present disclosure.

The present disclosure provides, in part, modules for modularmanufacturing systems. The modules can take on a plurality of forms,sizes, shapes, and/or configurations, examples of which are illustratedin the figures. Any suitable number of modules can be provided in aparticular modular manufacturing system depending on a particularmanufacturing need and/or manufacturing facility space limitation orrequirement. As few as one module can be used to manufacture a productas well, but, in most instances, at least two modules can be combined toform a modular manufacturing system. The modules can be configured tomanufacture, create, package, bottle, group, modify, transform, treat,orient, and/or combine, for example, (hereafter referred to together as“manufacturing”) one or more products. The modules can each perform oneor more functions. The products made by the modules can be the same typeof products, different types of products, differently sized products,and/or the same type of products with different features. In oneembodiment, a first product can be first size and a second product canbe a second size. In still other embodiments, packages of or grouping ofproducts created by the modules can have a plurality of different sizesand shapes, even for the same products.

In various embodiments, some example products that can be manufactured,or at least partially manufactured, by the modules of the presentdisclosure are paper towels or rolls thereof, toilet tissue or rollsthereof, shampoo, soap, dish soap, cosmetics, air fresheners, laundrydetergent, body washes, diapers, wet or dry wipes, tampons, sanitarynapkins, shaving devices and shaving gels, tooth paste and toothbrushes, dental floss, perfumes, lotions, batteries, cleaningimplements, dog food, snacks, medicines, over-the-counter drugs, fabricsofteners, deodorants, and/or cough drops. This list of products is byno means limiting, as a plurality of other products can also bemanufactured by the modules of the present disclosure. In oneembodiment, the modules of the present disclosure can be used inmanufacturing processes for the automotive industry and the textileindustry, for example. The modules of the present disclosure can also beused in other manufacturing process in any other suitable industries.

One advantage of the modules of the present disclosure is that equipmentcan be easily mounted to the modules and removed from the modules whenchanging-over from manufacturing one product to another differentproduct (i.e., differently sized product, different product alltogether, or the same product with different features). In many relatedtechnology modular manufacturing systems, a change-over frommanufacturing one product to manufacturing another different product canbe quite time consuming and costly. In some instances, such achange-over may not even be possible for particular related art modules.The modules of the present disclosure, however, are configured for easychange-over, such as by modifying, moving, adding to, and/orreconfiguring equipment mounted to portion of the modules and/or bysimply replacing the equipment mounted to portions of the modules. Suchreplacement can be accomplished by merely unattaching a piece ofequipment mounted to portions of the module, removing the piece ofequipment from the portion of the module, and mounting another piece ofequipment to the portion of the module. In one embodiment, equipment canbe held to the portions of the modules using bolts, pins, rods,quick-connect mechanisms, and/or other attachment devices. It isnoteworthy, that, in one embodiment, the equipment, as defined below,mounted within the modules can be completely contained within a frame ofeach of the modules and does not extend from the modules. Stated anotherway, the equipment does not extend past the perimeter of each module.This feature provides for easy change out of an entire module in amodular manufacturing system without the need to “untangle” equipmentextending between more than one module or extending outside of a frameof a module.

Each module of the present disclosure can be the same or similar suchthat the modules can be universally used in a manufacturing system. Eachmodule can comprise core elements, as a starting point (e.g., carriage,base, equipment mounts, utility corridor), and then equipment can bemounted to the module to provide the module with its desiredfunctionality. In one embodiment, the size of each module can differ orbe the same while still having the same core elements. For example, oneor more normal sized modules, one or more supersized modules, and one ormore small sized modules can be provided in a single modularmanufacturing system. All of these modules or some of these modules canbe used in a particular modular manufacturing system based on theparticular manufacturing need. In other embodiments, each module of amodular manufacturing system can be the same, except possibly for theequipment mounted to each module. In any event, the core elements ofeach module can be the same, or at least similar, to provide universal,interchangeable modules.

In various embodiments, each module of a modular manufacturing systemcan comprise one or more of the following: “plug and play” power andcommunication systems (e.g., cables, wireless) that can interact withother modules (either upstream or downstream) in a modular manufacturingsystem, utility corridors and/or conduits for wires and/or cables, andutilities (e.g., compressed air, vacuum systems, cooling air, water,steam). Each module can also comprise onboard electrical cabinets,integrated guard doors for safety, safety circuits, other safetyequipment, integrated lighting, standard operator interfaces, enclosuredoors, shields, and/or guards to at least inhibit dust and/or dirtinfiltration and reduce the noise produced by the module. In variousembodiments, portions of the modules can comprise insulation materialconfigured to at least inhibit sound and/or heat from escaping from themodules. In various embodiments, each module can also comprise one ormore mounting and alignment portions or plates for connecting to,operably engaging with, and/or aligning with neighboring modules,standard forklift pickup channels, chains, and/or hooks, process windowsize adjustment mechanisms, multi-layer product capability, multi-laneproduct capability, and/or built in and/or attached conveyors and/orfinished product conveyors. A module in the middle portion (i.e., not onone end) of a modular manufacturing system can be replaced withoutdisrupting the functionality of upstream or downstream modules. A middlemodule can also auto adjust for product quality, properties, features,and/or sizes, for example, without interfering with upstream ordownstream modules. In one embodiment, the modules of the presentdisclosure may not be sequence dependent in a particular modularmanufacturing system. As an example, a fifth module in a modularmanufacturing system can be interchanged with a second module in thesystem, for example. Such interchanging may require equipmentremounting. In one embodiment, some of all of the modules can havewheels or rollers attached thereto for easy manipulation of the modules.

In one embodiment, referring to FIGS. 1-4, a module 10 for a modularmanufacturing system can comprise a frame 12. The frame 12 can definethe perimeter of the module 10. In some embodiments, a return conveyor,not illustrated in FIGS. 1-4 (see e.g., FIG. 13), can be mounted to orformed with the frame 12 either inside or outside of the perimeterdefined by the frame 12. Optional mounting brackets 14 or openings canbe formed in or with the frame 12 or attached to the frame 12. Suchmounting brackets 14 or openings can be used to attach one module 10 toanother module 10, item, or piece of equipment. In other embodiments,the mounting brackets 14 may not be provided and a frame 12 of onemodule 10 can be mounted directly to a frame 12 of another adjacentmodule 10. In still other embodiments, the modules 10 in a manufacturingsystem or line can be positioned adjacent to each other without beingphysically attached to each other. In yet another embodiment, themodules 10 can be attached or engaged with each other using three-pointattachment, as illustrated in FIG. 1. Instead of using the bottommounting brackets 14, the mounting bracket 17 (shown in dash) can beused along with the top two mounting brackets 14. In such an embodiment,the two bottom mounting brackets 14 may not be provided. Suchthree-point attachment, in at least some embodiments, can allow forbetter engagement between the modules 10 when compared with four-pointattachment. The three points of attachment between the modules 10 can belocated at any suitable locations on the frame 12. Each mounting bracketin a three-point alignment system may only have one aperture in themounting brackets, for example. In one embodiment, the various mountingbrackets may be connected to each other using a T-shaped connector tomaintain the modules in alignment with each other.

In various embodiments, the frame 12 of each module 10 can define autility corridor 16 that can have conduits running therethrough forpower and communication lines. The conduits of a module 10 can alignwith conduits of other modules 10. The utility corridor 16, or otherportion of each module 10, can comprise operator panels, electricalpanels, safety circuits, cooling systems, vacuum systems, and/or lights,for example. In one embodiment, the utility corridor 16 can be locatedtowards a top portion of each module 10, but can also be located atother locations on each module 10. The frame 12 can also define a“process window” 18 (generally the region between the carriages) throughwhich a product or product packaging, or components of a product orproduct packaging (e.g., raw materials), can be conveyed or moved. Anymodifications, transformations, groupings, and/or packaging of theproduct can occur in the process window 18. The modules 10 can beconfigured to define a single lane or multiple lanes for product orproduct packaging moving therethrough as illustrated in FIGS. 1, 2, and4. In one example, rolls of paper products 20 are illustrated beingconveyed through the module 10, but the present disclosure is notlimited to such products.

The modules 10 can each comprise a carriage 22. The carriage 22 can bemovable relative to the frame 12 in directions generally perpendicularto product flow through the module 10. The direction of product flowthrough the module 10 can be parallel to, or generally parallel to, thelongitudinal axis of the rolls of paper product 20 in FIG. 2, forexample. In some embodiments, only one carriage 22 may be provided in amodule 10. In such an embodiment, a fixed plate or portion can bepositioned on the opposite side of the process window 18 as the singlecarriage 22. The carriage 22 can move toward and away from the fixedplate or portion to adjust the height or other dimension of the processwindow 18. In one embodiment, the carriage 22 can be a first carriage 22and a second carriage 24 can also be provided. The second carriage 24can be movable relative to the frame 12 and relative to the firstcarriage 22 in directions generally perpendicular to the direction ofproduct flow through the module 10. In such an instance, one or both ofthe first carriage 22 and the second carriage 24 can be moved towardand/or away from each other to adjust the height or other dimension ofthe process window 18. Other features of the various carriages of themodules 10 will be discussed in greater detail below.

In one embodiment, referring to FIG. 5, the module 10 can comprise thefirst carriage 22 and the second carriage 24. The first carriage 22 canbe movable relative to the second carriage 24 using height adjustmentmechanisms 21 as indicated in the figure. Width adjustment mechanisms 23can also be provided on the first carriage 22 and/or the second carriage24. These width adjustment mechanisms 23 can be integrated into thefirst carriage 22 and/or the second carriage 24. In one embodiment thesecond carriage 24 may or may not be moveable relative to the firstcarriage 22. In other embodiments, only the second carriage 24 may bemovable relative to the first carriage 22.

In one embodiment, FIG. 6 is a top view of the first carriage 22 engagedwith the frame 12 and FIG. 7 is a bottom view of the first carriage 22engaged with the frame. The first carriage 22 can comprise a first base26 and a second base 28. In one embodiment, only a single base may beprovided on the first carriage 22 and/or the second carriage 24. Inother embodiments, more than two bases may be provided on the firstcarriage and/or the second carriage 24. The first carriage 22 can movewithin the module 10 with respect to the frame 12 in directionsperpendicular to the direction of product flow through the module 10(e.g., in generally vertical directions). The first carriage 22 can movevia the use of the height adjustment mechanism 21 operably coupled tothe first carriage 22 (see e.g., FIG. 5). The height adjustmentmechanism 21 can comprise one or more threaded rods 30 that can berotated by an actuator or one or more bars or plates that are movablethrough the use of an actuator for example. Other adjustment mechanismsfor the first and second carriages 22 and 24 are described in greaterdetail below. The first carriage 22 can comprise one or more threadedapertures 32 that can each receive a portion of a threaded rod 30 formovement of the first carriage 22. As the actuator rotates the threadedrod 30 in a first direction, the first carriage 22 can move toward thesecond carriage 24 and as the actuator rotates the threaded rod 30 in asecond direction, the carriage 22 can move away from the second carriage24. In such an embodiment, the threaded rod 30 can be fixed, but can becapable of rotation so that the first carriage 22 can move relative tothe threaded rod 30. The first carriage 22 can be engaged with the frame12 using linear guides or guide tracks 33. In such an embodiment, thefirst carriage 22 can essentially be moved along a portion of the linearguides or guide tracks 33 when moving relative to the frame 12. Both ofthe first carriage 22 and the second carriage 24 can be completelycontained within the frame 12. In one embodiment, the first carriage 22can be fixed and the second carriage 24 can be movable (similar to orthe same as movement the first carriage 22 described above) or both ofthe first carriage 22 and second carriage 24 can be fixed within themodules 10. In still other embodiments, both of the first carriage 22and the second carriage 24 can be movable about the one or more threadedrods 30.

In one embodiment, still referring to FIGS. 6 and 7, the first base 26can comprise at least one equipment mount movably engaged with the firstbase 26. In various embodiments, the first base 26 can comprise a firstequipment mount 34 and a second equipment mount 36 movably engaged withthe first base 26. The first and second equipment mounts 34 and 36 canslide or move along one or more tracks 27 (see FIG. 7) defined in thefirst base 26 or attached to the first base 26, when moved by anadjustment assembly. The adjustment assembly can comprise an actuator40, such as a servo-motor, for example, configured to rotate a driveshaft 42. The drive shaft 42 can transmit rotation or torque to a gearbox 44 or directly to a secondary drive shaft 46. The gear box 44 cancomprise appropriate gearing, such as a pinion gear assembly, forexample, to rotate the secondary drive shaft 46 upon rotation of thedrive shaft 42. The gear box 44 can be a speed increasing gear box, aspeed decreasing gear box, or a one to one gear box. In one embodiment,the secondary drive shaft 46 can be a threaded rod or can be a rod withthreaded portions. In such an embodiment, the first equipment mount 34and the second equipment mount 36 can have threaded aperturestherethrough which are configured to receive portions of the threadedrod or at least the threaded portions of the threaded rod. Upon rotationof the secondary drive shaft 46, the first and second equipment mounts34 and 36 can move toward or away from each other. The threads definedat least partially through the threaded apertures of the first andsecond equipment mounts 34 and 36 can be opposite to each other so thatmovement of the first and second equipment mounts 34 and 36, in unison,toward or away from each other can be accomplished. If movement of thefirst and second equipment mounts 34 and 36 in the same direction isdesired, the threads of the threaded apertures can be the same as eachother (i.e., the first equipment mount 34 moves in the same direction asthe second equipment mount 36). In one embodiment, the threadedapertures on the first equipment mount 34 can have a different pitchthan the threaded apertures on the second equipment mount 36. Such afeature can allow the first and second equipment mounts 34 and 36 tomove toward and/or away from each other at different speeds when thesecondary drive shaft 46 is rotated. In one embodiment, the first andsecond equipment mounts 34 and 36 can be operably linked to separatedrive shafts or secondary drive shafts such that independent movement ofthe first equipment mount 34 relative to the second equipment mount 36can be accomplished. This feature can be useful in a situation wherefunneling of the lanes of product through the module 10 is required. Invarious embodiments, the drive shaft 42 may not be provided and thesecondary drive shaft 46 can be driven by an actuator, such as a motor,for example. Other equipment mounts, or pairs of equipment mounts,described herein can move in a similar fashion or the same fashion asdescribed above.

In one embodiment, the first base 26 can comprise a third equipmentmount 48 and a fourth equipment mount 50. The third and fourth equipmentmounts 48 and 50 can move toward and away from each other, in unison,(or in the same direction) using a second adjustment assembly that isthe same as, or similar to, the first adjustment assembly describedabove. As such, the second adjustment assembly can comprise an actuator40′, a drive shaft 42′, a gear box 44′, and a secondary drive shaft 46′.The third and fourth equipment mounts 48 and 50 can move independent ofthe first and second equipment mounts 34 and 36 owing to the provisionof the second adjustment assembly. In one embodiment, the secondadjustment assembly may not be provided and all of the first, second,third, and fourth equipment mounts 34, 36, 48, and 50 can be operablylinked to the first adjustment assembly and/or to the same secondarydrive shaft. In such an instance, the first and the second equipmentmounts 34 and 36 can move toward or away from each other as the thirdand fourth equipment mounts 48 and 50 move toward or away from eachother.

In various embodiments, any suitable number of equipment mounts can beprovided on the first base 26 or another base, such as one, two, four,six, eight, ten, twelve, fourteen, or sixteen, for example. In oneembodiment, each equipment mount can correspond to a product lane (evennumber of product lanes) for a roll of toilet tissue or paper towels,for example. In other embodiments, if lane guides are mounted to theequipment mounts, the product lanes can exist between the equipmentmounts to provide an odd number of product lanes. If an odd number ofequipment mounts are desired on the first base 26, or another base, anadditional equipment mount 39 (illustrated in dash in FIG. 7) can beprovided on the first base 26 in a central portion thereof proximate to,or between, an axis of the drive shaft 42 and the drive shaft 42′. Insuch an embodiment, three, five, seven, nine, eleven, or thirteenproduct lanes can be provided. In such an embodiment with the additionalequipment mount 39, if lane guides are mounted to the equipment mounts,an even number of product lanes can be provided. The additionalequipment mount 39 is described in greater detail below with referenceto FIG. 7B.

In one embodiment, the second base 28 can be the same as or similar tothe first base 26 described above. As such, the second base 28 cancomprise a first equipment mount 34′, a second equipment mount 36′, athird equipment mount 48′, and a fourth equipment mount 50′. Theequipment mounts 34′, 36′, 48′, and 50′ on the second base 28 can movesimilar to or the same as that described above with respect to theequipment mounts on the first base 26, including reference to theactuators 40 and 40′, the drive shafts 42 and 42′, secondary driveshafts 46″ and 46″, and gear boxes 44″ and 44′″. The second base 28 canalso comprise five or more equipment mounts, only two equipment mounts,or even only one equipment mount. If only one equipment mount isprovided, it can be fixed or movable (using one of the adjustmentassemblies). In one embodiment, the first equipment mount 34 and thesecond equipment mount 36 on the first base 26 can move in unison with,or together with, the first equipment mount 34′ and the second equipmentmount 36′ on the second base 28. Stated another way, rotation of thedrive shaft 42 by the actuator 40 can cause the secondary drive shafts46 and 46″ to rotate, thereby moving the first and second equipmentmounts 34 and 36 on the first base 26 and moving the first and secondequipment mounts 34′ and 36′ on the second base 28 in unison ortogether. The first and second equipment mounts 34′ and 36′ can bereferred to as a third equipment mount 34′ and a fourth equipment mount36′ if only the first and second equipment mounts 34 and 36 are providedon the first base 26 (and not the third and fourth equipment mounts 48and 50). In one embodiment, the third and fourth equipment mounts 48′and 50′ on the second base 28 can move in unison, or together with, thethird and fourth equipment mounts 48 and 50 on the first base 26 usingthe second adjustment assembly. Stated another way, rotation of thedrive shaft 42′ by the actuator 40′ can cause the secondary drive shafts46′ and 46′″ to rotate, thereby moving the third and fourth equipmentmounts 48 and 50 on the first base 26 and moving the third and fourthequipment mounts 48′ and 50′ on the second base 28 in unison ortogether. In various embodiments, the third and fourth equipment mounts48 and 50 on the first base 26 can move toward or away from each otherat a different speed (different thread pitch in threaded apertures) thanthe third and fourth equipment mounts 48′ and 50′, for example. In oneembodiment, the first base 26 can have a different number of equipmentmounts as the second base 28. In other embodiments, the first base 26can have the same number of equipment mounts as the second base 28. Eachequipment mount on each base can be the same size or a different size.In its most general form, the first carriage 22 may only have the firstbase 26 having one or two equipment mounts.

FIG. 7A is a top view of one embodiment of an equipment mount 35. Theequipment mount 35 can have one or more openings 37, such as threadedopenings, for example, that are configured to receive bolts or otherattachment members (e.g., pins, quick release fasteners, locking rods)extending from a piece of equipment. In other embodiments, the bolts orother attachment members can be separate from the piece of equipment andfrom the equipment mount 35 and can be engaged with both the openings 37and openings in the piece of equipment to secure the piece of equipmentto the equipment mount 35. In one embodiment, the openings 37 can haveany suitable shape, such as a circular shape or an elongate shape, forexample. Any suitable number or configuration of openings 37 can beprovided on or through the various equipment mounts. In one embodiment,the pattern of the openings 37 can be standard across all modules 10, orcan be different. In various embodiments, the equipment mount 35 andother equipment mounts of the present disclosure can have alignment pinsextending therefrom that can engage apertures in equipment being mountedthereto. Similarly, the apertures can be in the equipment mounts and thepins can extend from the equipment. This can aid in the alignment andcentering of the equipment with the equipment mounts. In someembodiments, it may be desirable to have equipment mounts with a narrowprofile in the machine direction (i.e., in the direction of product flowthough the module 10). This can allow the equipment mounts to collapsedown to a smaller center-to-center distance. In one embodiment, theequipment mounts may not have openings 37 and the equipment can beattached to the equipment mounts using quick release clamps fortool-less engagement.

FIG. 7B is a top view of an additional equipment mount 39 positionedintermediate the first equipment mount 34 and the second equipment mount36. Another additional equipment mount can also be positionedintermediate the first equipment mount 34′ and the second equipmentmount 36′. The additional equipment mount 39 can be located on the bases26 and 28, as illustrated in FIG. 7 by the dashed boxes. In oneembodiment, the additional equipment mount 39 can be centrally locatedabout the dashed line between the first equipment mount 34 and thesecond equipment mount 36. In various embodiments, the additionalequipment mount 39 can be fixedly attached to the tracks 27 (notillustrated in FIG. 7B) or can be slidably engaged with the tracks 27.In other embodiments, the additional equipment mount 39 can be fixedlyattached to one of the bases 26 and 28. If the additional equipmentmount 39 is slidably engaged with the tracks 27 or not rigidly attachedto a portion of one of the bases (i.e., floating), it can be linked tothe first and second equipment mounts 34 or 34′ and 36 or 36′ usinglinkage assemblies 43. The linkage assemblies 43 can allow theadditional equipment mount 39 to remain centered between the firstequipment mount 34 or 34′ and the second equipment mount 36 or 36′ evenafter such equipment mounts have been moved by the adjustment assembly.The linkage assemblies 43, owing to their scissor-like configuration,can compress or expand in the directions indicated by arrows A when thefirst equipment mount 34 or 34′ and the second equipment mount 36 or 36move toward or away from each other. As such, the distance X₁ and thedistance X₂ will be equal to, or at least substantially equal to, eachother independent of the position of the first and second equipmentmounts 34, 34′, 36, and 36′. One advantage of providing the additionalequipment mount 39 is to enable another piece of equipment to be mountedwithin a module. See, for example, FIGS. 1, 2, and 4 as an illustrationof a module with five lanes or five equipment mounts, the centerequipment mount being an additional equipment mount. Additionalequipment mounts can also be positioned at other locations on the firstbase 26, the second base 28, and/or on other bases described herein tosuit a particular manufacturing requirement.

In one embodiment, FIG. 8 is a top view of the second carriage 24engaged with the frame 12 and FIG. 9 is a bottom view of the secondcarriage 24 engaged with the frame 12. As discussed herein, the secondcarriage 24 may not be movable toward and away from the first carriage22, but instead, may be fixed relative to the frame 12. In such anembodiment, the first carriage 22 may be moveable relative to the secondcarriage 24 and the frame 12. The second carriage 24 can have the samecomponents as the first carriage 22 or different components as the firstcarriage 22. The second carriage 24 can function in the same or asimilar fashion as the first carriage 22 and therefore, itsfunctionality will not be described again here for brevity. The similarcomponents of the second carriage 24 are numbered in FIGS. 8 and 9 likethe components of the first carriage 22 illustrated in FIGS. 6 and 7 toillustrate that these components are the same or similar on bothcarriages 22 and 24.

In various embodiments, referring to FIGS. 8, 10, and 11, the first base26 of the second carriage 24 can comprise a first additional base 72 anda second additional base 74 extending therefrom. The first and secondadditional bases 72 and 74 can be movable with the second carriage 24 orcan be fixed, if the second carriage 24 is fixed. In other embodiments,the second carriage 24 can be movable and the first and secondadditional bases 72 and 74 can be fixed. The first and second additionalbases 72 and 74 can extend vertically, or generally vertically, withinone or more modules 10. These additional bases 72 and 74 can be providedon each module 10 to help support and/or drive layers or planes ofproduct moving through the process window 18. The additional bases 72and 74 can comprise one or more equipment mounts 58, which are movablerelative to the bases 72 and 74, as described below. The equipmentmounts 58 can be the same as or similar to that described above withrespect to equipment mounts 34 and 36, for example. The second base 28can comprise a third additional base 76 and a fourth additional base 78similar to, or the same as, the first additional base 72 and the secondadditional base 74. In other various embodiments, the various additionalbases can be attached to or extend from the first base 26 and/or thesecond base 28 of the first carriage 22. In still other variousembodiments, the various additional bases can be engaged with the frame12 or movably engaged with the frame 12, for example. In such anembodiment, the additional bases can be mounted on separate additionalcarriages, for example.

FIG. 10 is a side view of a portion of the module 10 and FIG. 11 is afront view of the portion of the module 10. In one embodiment, referringto FIGS. 8, 10, and 11, the second carriage 24 can comprise one or moreadditional bases 72, 74, 76, and 78 as described above. These additionalbases 72, 74, 76, and 78 can move with the second carriage 24 orindependent of the second carriage 24 in directions toward and away fromthe first carriage 22 and in directions generally perpendicular to thedirection of product flow through the module 10. The additional bases72, 74, 76, and 78 can also move toward and away from each other indirections generally perpendicular to the direction of product flowthrough the module 10 and generally perpendicular to the directions ofmovement of the first and second carriages 22 and 24. The equipmentmounts 58 can move as described above in directions generallyperpendicular to the direction of product flow through the module 10 andin directions generally perpendicular to the directions of movement ofthe first and second carriages 22 and 24. The additional bases 72, 74,76, and 78 can each comprise one or more additional equipment mounts(like additional equipment mount 39), for reasons similar to thatdescribed above. Although not required, one benefit of providing theadditional bases 72, 74, 76, and 78 is to provide additional equipmentmounted on the equipment mounts 58 that are helpful in the manufacturingof the product passing through the modules 10, especially layers orstacks of product. In one embodiment, the equipment mounts 58 can bemovably engaged with a track 60, similar to the equipment mountsdescribed above. The equipment mounts 58 can move in unison in the samedirection. In other various embodiments, the equipment mounts 58 canmove, in unison, toward and away from each other. The equipment mounts58 can also move independent of each other and can have a separateactuation assembly. In any event, movement can be accomplished throughthe use of an actuator 62 which is configured to rotate a drive shaft64. The drive shaft 64 can be threadably engaged with threaded aperturesin each of the equipment mounts 58. The threads of the threadedapertures can be oriented such that the equipment mounts 58 travel inone direction (e.g., upwardly) or in the other direction (e.g.,downwardly) about the drive shaft 64. In other various embodiments, thethreads of the threaded apertures can be oriented such that oneequipment mount 58 moves in a first direction while another equipmentmount 58 moves in a different direction about the drive shaft 64.

In one embodiment, referring to FIGS. 10 and 11, one or more actuators63 can rotate one or more drive shafts 65 which can be operably linkedto one or more threaded rods 30 via one or more gear boxes 67. The gearboxes 67 can transmit rotational motion or torque of the drive shafts 65to the threaded rods 30 as is understood by those of skill in the art tomove the first carriage 22 and/or the second carriage 24. The gear box67 can be a speed increase gear box, a speed decreasing gear box, or aone to one gear box, for example.

In one embodiment, rolls of paper products, such as rolls of toilettissue and/or rolls of paper towels, for example, can be processed usingthe modules and modular manufacturing systems of the present disclosure.One issue with packaging or bundling rolls of paper products ismaintaining control of the rolls. This can be difficult at times owingto the cylindrical shape of the rolls. Rolls can sometimes be processedfor packaging when lying on their curved outer surfaces (see e.g., FIGS.1 and 2, element 20). By providing the additional bases 72, 74, 76, and78 described above, the rolls of paper product can be better controlled,and inhibited from rolling movement, within the modules 10. This canalso help maintain the rolls of paper product in their lanes whilemoving over or through the equipment mounted to each equipment mount.When the equipment mounted to the various equipment mounts acts on aproduct, the equipment is generally only effective where it contacts theproduct. For conveyor belts acting on radial portions of a cylindricalroll, the conveyor belt may only be effective on a small portion of thecircumference of the roll. As a result, a very narrow conveyor belt canmove product similar to a very wide conveyor belt, if the position ofthe narrow conveyor belt is adjusted in the cross-direction (i.e.,generally perpendicular to the direction of product flow through themodules 10) so that the centerline of each narrow conveyor belt is closeto the centerline of each roll moving through the module 10.

In one embodiment, again referring to FIGS. 10 and 11, the first andsecond carriages 22 and 24 can be moved to the outer perimeter of theprocess window 18 or to outside of the process window 18 to mountequipment to the various equipment mounts, to remove equipment from theequipment mounts, and/or to perform maintenance on the equipment. Byallowing the first and second carriages 22 and 24 to move to the outerperimeter of the process window 18 or to outside of the process window18, the equipment on the first carriage 22 is moved a sufficientdistance away from the equipment on to the second carriage 24, therebyproviding working space within the process window 18. Such working spacecan provide easy access to the bolts or other attachment means mountingthe equipment to the equipment mounts for easy change out, replacement,and/or maintenance. In various embodiments, one advantage of the modules10 of the present disclosure is that the adjustment of the equipmentwithin the process window 18 is made by the various carriages andequipment mounts and not by the equipment. In this way, the equipment isindependent of the modules 10 and can easily be removed by detaching itfrom the mounts and unplugging any motors and/or sensors, for example.One main purpose of the adjustability of the various carriages and theequipment mounts is to provide “push button” changeover capability andprovide the ability to adjust the positions of the equipment withoutshutting down the module 10. In one embodiment, the adjustment can beprovided to optimize the manufacturing process to the varying propertiesof the product or raw material entering each module 10. Any of theactuators discussed herein can be replaced by one or more manualadjustment mechanisms (e.g., hand cranks or handwheels) where theautomatic adjustment is not desired or needed.

In one embodiment, referring to FIGS. 12 and 13, another first carriage22′ is disclosed. The first carriage 22′ is similar to the firstcarriage 22, but the first and second equipment mounts 34 and 36 on afirst base 26′ are independently controlled from the first and secondequipment mounts 34′ and 36′ on a second base 28′. This independentcontrol of the first and second the equipment mounts is accomplished byproviding an actuator 31 or 31′ operably engaged with a gear box 45 or45′ that is operably engaged with the secondary drive shaft 46 or 46′″.Such a feature can enable the first and second equipment mounts 34 and36 on the first base 26′ to move independent of the first and secondequipment mounts 34′ and 36′ on the second base 28′. Likewise, third andfourth equipment mounts 48 and 50 on the first base 26′ can beindependently controlled from third and fourth equipment mounts 48′ and50′ on the second base 28′. This independent control of the third andfourth equipment mounts is accomplished by providing an actuator 25 or25′ operably engaged with a gear box 47 or 47′ that is operably engagedwith the secondary drive shaft 46′ or 46″. Such a feature can enable thethird and fourth equipment mounts 48 and 50 on the first base 26′ tomove independent of the third and fourth equipment mounts 48′ and 50′ onthe second base 28′. The actuators 31 or 31′, the gear boxes 45 or 45′or 47 or 47′, and the secondary drive shafts 46 or 46′″ or 46′ or 46″can together be referred to as an “adjustment assembly”. The equipmentmounts can be slidably engaged with one or more tracks as discussedabove. Although not illustrated, a second carriage 24 can have the samefeatures as the first carriage 22′ to provide independent control to theequipment mounts on the first and second bases thereof. The otherfeatures of the first carriage 22′ can be the same as or similar to thatdescribed above with respect to the first carriage 22 and will not bediscussed again here for brevity.

In one embodiment, referring to FIG. 14, a frame 12′ for a module of thepresent disclosure is illustrated. One or more adjustment mechanisms 13(such as width and height adjustment mechanisms) are engaged with theframe 12′. The adjustment mechanisms 13 can each comprise an adjustmentmember 110 configured to move the carriages relative to and within theframe 12′. The adjustment member 110 can move along a threaded rod 112when the threaded rod 112 is rotated by actuators operably engaged withgear boxes 114. The frame 12′ can be comprised of a tubular framestructure that can be hollow or solid. The weight of the equipmentattached to bases of the carriages can be supported by the tubular framestructure.

In another embodiment, referring to FIG. 15, a frame 12″ for a module ofthe present disclosure is illustrated. One or more adjustment mechanisms13 (such as width and height adjustment mechanisms) can be engaged withthe frame 12″. The various carriages of the present disclosure can beattached to the adjustment members 110 of the adjustment mechanisms 13such that the carriages can be moved relative to and within the frame12′. The adjustment mechanism 13 and the manner of movement of theadjustment members 110 can be the same as or similar to that describedabove with respect to frame 12′. The frame 12″ can comprise a base plate116. The base plate 116 can support the vertically extending portion ofthe frame 12″. As a result, the various carriages and equipment mountedto bases of the carriages can be supported by the base plate 116 and thevertically extending portion of the frame 12″. FIGS. 14 and 15 merelyillustrate two different non-limiting examples of frame structures thatcan be used as a frame for the modules of the present disclosure. FIGS.16 and 17 illustrate example modules, or portions thereof, built on theframe 12″ of FIG. 15. Some of the components of FIG. 16 have beenremoved in FIG. 17 for clarity in illustrating the frame 12″ and thebase plate 116.

In various embodiments, referring to FIGS. 18-20, an example module 100with various components removed is illustrated. FIGS. 18-20 all showfront views of the example module 100. The perimeter and/or frame of themodule 100 is defined by the outer dashed rectangle in FIG. 18 and theprocess window 118 is defined by the inner dashed rectangle in FIG. 18.The process window 118 is also illustrated in FIGS. 19 and 20. Theprocess window 118 defines the largest space for product within aparticular module. The process window 118 can be made smaller or largerbased on the size of the module or based on the equipment positionedwithin the module. The various bases are illustrated without associatedcarriages, a module frame, and various other structures of the modules,for example, for clarity in illustration. The module 100 can comprise afixed (in position) or movable bottom conveyor 130 on which rolls ofpaper product 20 can travel. The direction of movement of the rolls ofpaper product 20 through the module 100 is into or out of the page inFIGS. 18-20. The module 100 can comprise a first base 126, a first sidebase 128, and a second side base 138. In one embodiment, the first base126, the first side base 128, and the second side base 138 can eachcomprise more than one base, although only one is illustrated because ofthe front view illustrated in the figures. Examples of two baseconfigurations on a carriage are illustrated in FIGS. 12 and 13, forexample. In various embodiments, one or more of the bases 126, 128, and138 may not be provided. The first base 126, the first side base 128,the second side base 138, and the conveyor 130 can surround, at leastpartially surround the process window 118 and/or extend into the processwindow 118. As discussed herein, the process window 118 can define themaximum dimensions of product that the module 100 can processtherethrough.

In various embodiments, each of the bases can have equipment 132, suchas conveyor supports and conveyors or other equipment, for example,mounted to equipment mounts 134 thereof. One or more of the equipmentmounts 134 can be movable along a threaded rod 136 or other movementmechanism. By allowing all or some of the equipment mounts 134 to moverelative to each base, the equipment 132 can be adjusted for the sizeand number of product within the process window 118 (see FIG. 18 vs.FIG. 20 and note how the equipment 132 can move relative to the rolls ofpaper product 20 or other product being processed). At least one of thebases, such as the first base 126, for example, can define apertures orslots therethrough. A portion of, or all of, the equipment 132 can beretracted through the apertures or slots as the first base 126 and thethreaded rod 136 move toward the conveyor 130. In one embodiment,referring to FIGS. 19 and 20, some equipment 132 can be retracted, whileother equipment 132 may not be retracted for certain configurations ofproduct being processed in the process window 118. The first and secondside bases 128 and 138 can move into toward and away from a centralportion of the process window 118 (i.e., into and out of the processwindow 118). In FIG. 19, the first and second side bases 128 and 138 andtheir associated equipment 132 are moved more into the process window118 than in FIGS. 18 and 19. Referring again to FIGS. 18-20, it isillustrated how the module 100 can be used to process many differentconfigurations of rolls of paper products 20 or other products dependingon a particular manufacturing need. In FIG. 19, a small gap can bepresent between the equipment 132 extending from the first and secondside bases 128 and 138 that is not contacting the product and theequipment 132 extending from the first base 126.

In one embodiment, it can be desirable to convey or process rolled paperproducts or other rolled products using a V-shaped conveyor or conveyingmechanism to support the products. The V-shaped conveyor can be quiteuseful in conveying rolled products, such as rolled paper products,owing to the inherent stability that the rolled products have whilestacked on a V-shaped conveyor or conveying mechanism. Stated anotherway, the rolls have a reduced tendency to roll while stacked on theV-shaped conveyor or conveying mechanism. This stability can beprovided, at least in part, by supporting the rolled product from twosides with the V-shaped conveyor or conveying mechanism and throughgravity acting on the stack of rolled products. Stacks of rolls in adiamond shape or rhombus shape can have more stability than a cube orrectangular shaped stack of rolled products (e.g., FIG. 18). As such, byusing a V-shaped conveyor or conveying mechanism, better control ofrolled products can be achieved and, thereby, more efficient processingor packaging of the rolled products can be achieved. To achieve aV-shaped conveyor or conveying mechanism, the process window of a modulemay be rotated about 20 to about 70 degrees, about 40 to about 50degrees, or about 45 degrees, for example, as illustrated below.

In one embodiment, referring to FIGS. 21-24, another module 200 isillustrated. This module 200 can provide a “V-shaped” conveyor orconveying mechanism by providing a process window 218 (shown in dash inFIG. 23) that is rotated about 40 to about 50 degrees from thehorizontal. The module 200 can have similar components as discussedabove, such as a utility corridor, for example. These similar componentswill not be discussed again here for brevity. The module 200 cancomprise a frame 212. The frame 212 can have a different configurationas the frames discussed above to process a diamond, rhombus,parallelogram, trapezoidal, pentagonal, or other shaped stack of rollsof paper products within the process window 218 of the module 200. Themodule 200 with carriages can be seen in FIG. 21. The module 200 cancomprise four carriages, a first top carriage 202 (or first portion), asecond top carriage 204 (or second portion), a first bottom carriage 206(or first portion), and a second bottom carriage 208 (or secondportion). The first and second top carriages 202 and 204 can move inunison or independent of each other. Likewise, the first and secondbottom carriage can move in unison or independent of each other. Thefirst and second top carriages 202 and 204 can be independent of orseparate from each other and, likewise, the first and second bottomcarriages 206 and 208 can be independent of or separate from each other.In other embodiments, the first and second bottom carriages 206 and 208may be a single unit. The first and second bottom carriages 206 and 208can form a V-shaped product receiving space within the process window218. In other embodiments, bases mounted to the first and second bottomcarriages 206 and 208 can form a V-shaped product receiving space withinthe process window 218. The various carriages can be oriented so thatthe process window 218 can be diagonally oriented, as illustrated as anexample in FIG. 23. The frame 212 can comprise a tubular support section214 extending from a base plate 216. The tubular support section 214 cancomprise one or more projections 216, such as triangular or otherwiseshaped projections, extending from each side of the frame 212. Thevarious carriages can be engaged with or movably engaged with portionsof the projections 216 or other portions of the frame 212. In oneembodiment, the first and second bottom carriages 206 and 208 can befixed and the first and second top carriages 202 and 204 can move withrespect to the first and second bottom carriages 206 and 208 or viceversa. In another embodiment, the first and second bottom carriages 206and 208 and the first and second top carriages 202 and 204 can movetoward and away from each other. In one embodiment, the first topcarriage 202 can move toward the second bottom carriage 208 and thesecond top carriage 204 can move towards the first bottom carriage 206.FIG. 22 is a view of the module 200 with various components removed forclarity in illustration.

In one embodiment, referring to FIG. 23, example bases with equipment230 mounted thereon and rolls of paper products positioned within theprocess window 218 are illustrated. The frame 212 is provided in FIG. 23to illustrate how the bases and equipment 230 can be situated within themodule 200. The various carriages are not illustrated in FIG. 23. As anexample, the arrows in FIG. 23 indicate the direction of movement of thebases via movement of the carriages. A first base 220 can be engagedwith the first top carriage 202 and a second base 222 can be engagedwith the second top carriage 204. Likewise, a first base 224 can beengaged with the first bottom carriage 206 and a second base 226 can beengaged with the second bottom carriage 208. Either of or both of thefirst base 224 and the second base 226 can comprise a conveyor engagedtherewith.

In various embodiments, referring to FIGS. 24-26, the various bases 220,222, 224, and 226 can have equipment mounts 232 engaged with equipment230. The equipment 230 can comprise conveyor supports and conveyors, forexample. The rolls of paper product 20 can rest on a V-shaped conveyorformed by conveyors of the third base 224 and the fourth base 226. Thefirst base 220, the second base 222, the third base 224, and the fourthbase 226 can surround, or at least partially surround, the processwindow 218 and/or can extend into the process window 218. Any or all ofthe equipment mounts 232 can be movable with respect to the base thatthey are mounted on using a threaded rod 234 or other movementmechanism. The threaded rod 234 can be rotated by an actuator and/orother device to move the equipment mounts 232. Such movement of theequipment mounts 232 can allow the equipment 230 mounted thereto toadjust for particular product dimensions and number within the processwindow 218 (see, for example, the spacing of the equipment mounts 232,and thereby the equipment 230 in FIG. 24 vs. FIG. 26). In oneembodiment, the modules 200 can be adjustable to accommodate anysuitable number and/or size of products within the process window 218.The process window 218, in some embodiments, can be large enough toaccommodate product for a large count package. In various embodiments,the equipment 230 on the second base 222 may be longer than theequipment 230 on the other bases 220, 224, and 226. In otherembodiments, the equipment 230 on another base can be longer or all ofthe equipment 230 can be the same length or a different length. Thevarious bases can function in the same, or a similar, fashion as thatdescribed above with respect to FIGS. 18-20 and can process any suitablenumber and size of rolled products. Referring to FIG. 25, a gap can bepositioned between any equipment 230 not contacting the product 20 andother equipment 230, similar to that explained above.

FIG. 27 is a diagram of one example of a modular manufacturing systemcomprising a plurality of modules 10 of the present disclosure. Themodules are labeled according to their function in a rolled paperproduct packaging process. In one embodiment, example dimensions of asingle module can be 1.99 meters in length by 2.0 meters in width. Themodules, however, can have any suitable height, length, and/or width.

In various embodiments, the modules of the present disclosure can beused in manufacturing paper towels, toilet tissue, facial tissue, wet ordry wipes, diapers, sanitary napkins, and/or cleaning substrates, forexample. In one embodiment, the modules can be used in a convertingprocess of paper making and/or a packaging process for rolls of fibrousmaterials or paper products (e.g., paper towels, facial tissue, and/ortoilet tissue). The modules can have any suitable equipment for theseprocesses mounted to them so that they can each perform a specificfunction or functions. In one embodiment, two modules positioned inseries in a manufacturing line may perform the same function, a similarfunction, or a different function. In various embodiments, some of themodules may be positioned in parallel with other modules in amanufacturing line and may perform the same or a different function.Equipment having different shapes and/or sizes or the same shapes and/orsizes can be mounted to the various modules, or bases thereof, withoutthe need for replacement of the components of the modules (i.e., thesame carriages, bases, additional bases, and equipment mounts can beused). In various embodiments, some equipment mounts on the bases maynot be utilized in certain circumstances, depending on the equipmentbeing attached to the carriages of the modules. Some examples offunctions that can be performed by the modules in a fibrous materialroll or paper product roll packaging line are described below. Thesefunctions can be performed in the order described or in any othersuitable order.

Metering Module—

One or more lanes of rolls or packs (i.e., more than one roll within apolymer film or other film) of fibrous materials (e.g., paper towelsand/or toilet tissue) are fed into a metering module. In this examplemetering module, multiple conveyor belt mechanisms can be attached toequipment mounts on the bases of the first carriage and the secondcarriage (see e.g., FIGS. 1-4). Such mounting can form individual topand bottom driven lanes that output one or more lanes of rolls or packsof fibrous materials (up to the number of infeed lanes). The equipmentmounts can be adjusted such that the center-to-center distance of thelanes corresponds to, or generally corresponds to, the width of therolls or packs being fed through the lanes.

Robotic Module—

One or more lanes of rolls or packs of fibrous materials can be fed intoa robotic module. The robotic module can comprise a robot configured topick up one or more of the rolls or packs of fibrous materials andassemble them on a conveying mechanism, such as a V-shaped conveyingmechanism. The conveying mechanism can be comprised of one or moreconveyors and/or guiderails. The conveying mechanism components can bemounted to equipment mounts on the bottom carriage.

Pushing Module—

One or more lanes of rolls or pack of fibrous materials can be fed intoa pushing module. The pushing module can comprise a pusher mounted tothe equipment mounts of the top carriage or to a fixed positionoverhead. The pusher can act on the rolls or packs of fibrous materialsto separate, group, orient, and/or transfer the rolls or packs on aconveying mechanism, such as V-shaped conveying mechanism. The conveyingmechanism can comprise one or more conveyors, lifting mechanisms, and/orguiderails, for example. The conveying mechanism components can bemounted to the equipment mounts of the bottom carriage.

Stacking Module—

One or more lanes of rolls or packs of fibrous materials can be fed intoa stacking module. A wide belt mechanism can be attached to theequipment mounts on the bases of the second carriage. Optionally, asecond wide belt mechanism can be attached to the equipment mounts onthe bases of the first carriage. In such an embodiment, the equipmentmounts for the wide belt mechanisms can remain stationary, as no lateraladjustment is usually required. In various embodiments, guide rails canbe mounted to the equipment mounts on the additional bases or sidebases. Such guide rails can be moveable and/or adjustable. The guiderails can provide side support to the rolls or packs of fibrousmaterials being conveyed through the stacking module. The wide beltmechanisms can pivot in a generally vertical direction to place therolls or packs of fibrous materials into multiple vertical layers. Thelayer or layers of rolls or packs of fibrous material can be supportedby shelves which can be supported by the vertically-adjusting equipmentmounts on the one or more additional bases. The equipment mounts on theadditional bases can be adjusted so that the spacing between the shelvescorresponds to the height or other dimension of the rolls or packs.

Forming Module—

One or more lanes of rolls or packs of fibrous materials in one or morelayers can be fed into a forming module. Conveyor belt mechanism can beattached to the equipment mounts on the bases of the first carriage, thebases of the second carriage, and/or one or more of the additional basesor side bases. All or some of the equipment mounts can adjust to alignthe conveyor belts of the conveyor belt mechanisms with the centerlinesof the rolls or packs of fibrous materials being conveyed through theforming module. The rolls or packs of fibrous materials can be conveyedthrough one or more formers while being enveloped in a film or a polymerfilm (provided by a Film Feed Module). The polymer film can then bejoined to form a tube (with open ends) around the rolls or packs offibrous materials. If one or more of the formers is to be fixed, theformer(s) can be attached to the additional equipment mount or otherstationary equipment mounts, for example. If one or more of the formersis to be adjustable, the former(s) can be attached to equipment mountson the bases of the first carriage, the bases of the second carriage,and/or one or more of the additional bases.

Folding Module—

The packs or rolls of fibrous materials can be fed into a foldingmodule. Such packs or rolls can be enveloped in the polymer film tube asdescribed in the forming module section above. Conveyor belt mechanisms,folding plates, and folding mechanisms can be attached to equipmentmounts on the bases of the first and second carriages. The equipmentmounts can be adjusted to correspond with the pack or rolls dimensions(e.g., height, width).

End Sealing Module—

The packs or rolls of fibrous materials enveloped in the closed butunsealed polymer film tube can be fed into an end sealing module. Sideconveyor belt mechanisms with heater blocks can be attached to equipmentmounts on the bases of the second carriage. The enveloped packs or rollsof fibrous materials can be conveyed through the module while beingheat-sealed.

Die Sealing Module—

The packs or rolls of fibrous materials enveloped in the closed butunsealed polymer film tube can be fed into a die sealing module. Diesealing mechanisms and gusset seal forming mechanisms can be attached tothe equipment mounts of the bases of the first and second carriages. Thedie sealing die mechanisms can be positioned on stationary equipmentmounts (or on equipment mounts that can remain stationary), while thegusset seal forming mechanisms can be positioned on adjustable equipmentmounts. A conveyor belt mechanism can be attached to equipment mounts onthe bases of the second carriage for conveying the enveloped packs orrolls of fibrous materials through the die sealing module.

Manipulation Module—

One or more lanes of rolls of fibrous materials, enveloped rolls offibrous materials, enveloped packs of rolls of fibrous materials, packsof fibrous materials, bundles of fibrous materials, knock down flats(i.e., flattened cases), unfilled cases, cases filed with rolls or packsof fibrous materials, and/or closed cases of rolls or packs of fibrousmaterials can be fed into a manipulation module. A combination ofconveyor belt mechanisms and lane guides can be attached to theequipment mounts on the bases of the first carriage, the bases of thesecond carriage, and/or one or more of the additional bases or sidebases. These equipment mounts may need to remain stationary or adjustdepending on the manipulation step being performed. Robotic mechanismscan also be attached to any of the equipment mounts and/or the frame.Manipulation steps can comprise rotation, upending, knocking over,grouping, orienting, and/or laning, for example, to position the rolls,packs, and/or bundles of fibrous materials into an orientation and/orconfiguration required by a downstream module or a downstream process.

Case Forming Module—

One or more knock down flats can be fed into a case forming module.Conveyor belt mechanisms, guiderails, opener arms, and closer arms canbe attached to equipment mounts on the bases of the first and secondcarriages. Glue or tape applicators can be attached to various equipmentmounts on one or more of the additional bases or side bases. The outputfrom the case forming module can be a vertically erected case that isclosed and sealed on one end with the other end being open and unsealedfor case loading.

Case Loading Module—

One or more erected cases and one or more layers of rolls, packs, and/orbundles of fibrous materials can be fed into a case loading module.Conveyor belt mechanisms, pushers, and/or lane guides, for example, canbe attached to equipment mounts on the bases of the first carriage, thebases of the second carriage, and/or one or more of the additionalbases. The case loading module can output a filled, but open andunsealed case.

Case Closing Module—

One or more of the filled cases can be fed into a case closing module.Conveyor belt mechanisms, guiderails, and/or closer arms, for example,can be attached to the equipment mounts on the bases of the first andsecond carriages. Glue or tape applicators can be attached to variousequipment mounts on one or more of the additional bases. The caseclosing module can output a filled, sealed case of packs or rolls offibrous materials.

FIG. 28 is an illustration of a modular manufacturing system comprisinga plurality of modules 10 of the present disclosure. In such anembodiment, a portion of a return conveyor 66 is mounted to or formedwith the modules 10 outside of the frame 12. In other embodiments, aportion of the return conveyor 66 is engaged with an outer portion of atleast some of the modules 10. In other embodiments, the return conveyor66 can be mounted within the frame 12. The return conveyor 66 can beused to convey finished product, partially finished product, unfinishedproduct, and/or packaged product (hereafter together referred to as“finished product 68”), after the finished product 68 has run throughthe modular manufacturing system. The return conveyor 66 can alsocomprise a spiral section 70 configured to redirect the finished product68 for shipping, palletizing, and/or for additional manufacturing, suchas label application and/or printing. In one embodiment, the spiralsection 70 can raise or lower the height of the finished product 68 withrespect to the height of the return conveyor 66. The spiral section 70can convey the finished product 68 to another conveyor.

The term “conveyor,” as used herein, describes any device that can movean object over a distance, such as driven rolls, a fluid pressurized bedor belt with directionally oriented apertures in the bed or belt to pushproduct in a suitable direction, a belt operably positioned about one ormore driven rolls, non-driven rolls, and/or slides, for example.

The term “equipment,” as used herein, describes the process machinery,items, or devices that are configured to be attached to the equipmentmounts. Adjustment of the equipment can be decoupled from adjustment ofthe modules. Stated another way, the modules can be adjusted independentof any adjustments made to the equipment. In various embodiments, someequipment that can be attached to the equipment mounts of the bases ofthe carriages discussed herein can comprise packaging equipment, such aspushers, diverters, kickers, tuckers, manipulation devices, orientationdevices, compression devices, stretching devices, counting devices,conveyors, stackers, folders, lane guides, guide rails, sorters,printers, wrappers, bundlers, sealers, cappers, flippers, bottlers,dispensers, liquid, gel, and/or paste dispensers, application devices,handle application devices, chemical application devices, fragranceapplication devices, adhesive application devices, label applicationdevices, and/or melting devices, for example, and manufacturingequipment, such as dispensers, liquid, gel, and/or paste, dispensers,folders, converters, printers, melting devices, heating devices, coolingdevices, mixing devices, spraying devices, holding devices, fragranceapplication devices, chemical application devices, label applicationdevices, and/or adhesive application devices. Other suitable equipmentfor any manufacturing process can also be mounted to the equipmentmounts. In one embodiment, more than one piece of equipment can bemounted to a particular equipment mount or a single piece of equipmentcan be mounted to a particular equipment mount. In some embodiments, notall equipment mounts will have equipment mounted thereto for variousoperations.

In one embodiment, a modular manufacturing system is provided by thepresent disclosure. The system can comprise a first module comprising atleast a first piece of equipment and a second module comprising at leasta second piece of equipment. Any suitable number of pieces of equipmentcan be provided on each of the modules. Furthermore, any suitable numberof modules can be provided, such as three, four, or ten, for example, ina modular manufacturing line. The modules can be positioned adjacent toeach other or in parallel or in series. Gaps can be defined between atleast some of the modules. In one embodiment, the gaps can be about 0.5inches or greater, such as 1 inch, for example. In one embodiment, noequipment from the modules extends into the gaps between the variousmodules. Each of the modules of the module manufacturing system can havethe same features as discussed herein. In various embodiments, aconveyor can be positioned on or in each of the modules. In oneembodiment, a return conveyor, or a portion of a return conveyor, can bepositioned on an outer portion of each of the modules.

In one embodiment, a method for processing rolls of fibrous materials(e.g., paper towels, toilet tissue, facial tissue in single ormulti-ply, with any suitable type of fibers) is provided. The method cancomprise using a module comprising internal adjustment mechanisms,attaching a first piece of equipment to the module to enable the moduleto perform a first function, and adjusting the module for the firstpiece of equipment using the internal adjustment mechanisms. The methodcan further comprise removing the first piece of equipment from themodule, attaching a second piece of equipment to the module to enablethe module to perform a second function, and adjusting the module forthe second piece of equipment using the internal adjustment mechanisms.The first piece of equipment can be different than, similar to, or thesame as the second piece of equipment. The first function can bedifferent than, similar to, or the same as the second function. Eitheror both of the first piece of equipment and the second piece ofequipment can comprise more than one piece of equipment (e.g., aplurality of lane guides). The first and second functions can be one ofmetering, stacking, film feeding, cutting, trimming, flipping, rotating,orienting, forming, folding, end sealing, die sealing, manipulating,case forming, case loading, and case closing, for example. The modulecan be used in modular manufacturing systems with a plurality of othersimilar or the same modules.

In one embodiment, a method for processing rolls of fibrous materials(e.g., paper towels, toilet tissue, facial tissue in single ormulti-ply, with any suitable type of fibers) is provided. The method cancomprise using a first module and a second module. Each module cancomprise one or more internal adjustment mechanisms. The method canfurther comprise attaching a first piece of equipment to the firstmodule, adjusting the first piece of equipment using the internaladjustment mechanisms of the first module and independent of anyadjustment mechanisms on the first piece of equipment, attaching asecond piece of equipment to the second module, and adjusting the secondpiece of equipment using the internal adjustment mechanisms on thesecond module and independent of any adjustment mechanisms on the secondpiece of equipment. The first piece of equipment can be different than,similar to, or the same as the second piece of equipment. The firstmodule can be positioned adjacent to, in line with, proximate to, distalfrom, upstream of, or downstream of the second module. Any othersuitable number of modules can be used with the first module and thesecond module (e.g., upstream or downstream of the first module and thesecond module).

In one embodiment, a method of transporting rolls of a fibrous material,such as paper towels or toilet tissue, for example, is provided. Themethod can comprise providing a V-shaped conveying mechanism (see e.g.,FIG. 23 bottom carriage), stacking a plurality of the rolls of thefibrous material on the V-shaped conveying mechanism, and transportingthe plurality of the rolls of the fibrous material between a firstposition and a second position. The transporting step can beaccomplished through the use of a conveyor engaged with the bases 224and 226, for example. The first position and the second position can bewithin a single module or between a plurality of modules. The V-shapedconveying mechanism can be positioned within a module for a modularmanufacturing system. The V-shaped conveying mechanism can comprise acarriage comprising a first portion and a second portion. The firstportion and the second portion of the carriage can be separate from eachother or can form a unitary piece. If the first and second portions ofthe carriage are separate from each other, the method can compriseindependently moving the first portion or the second portion of thecarriage relative to the other portion. The method can further comprisepositioning the first portion and the second portion of the carriagesuch that an angle of about 90 degrees or about 120 degrees existstherebetween. In another embodiment, this angle can be in the range ofabout 50 degrees to about 170 degrees, specifically reciting all 1degree increments within the specified range. The plurality of the rollsof the fibrous material can comprise rolls of paper towel, rolls oftoilet tissue, or other rolled products, for example. Each roll of papertowels or toilet tissue can comprise a core forming a longitudinal axis.The stacking step can comprise stacking the rolls with a longitudinalaxis of each core thereof in a direction generally parallel to thedirection of transport between the first position and the secondposition. In other embodiments, stacking step can comprise stacking therolls with a longitudinal axis of each core thereof in a directiongenerally perpendicular to the direction of transport between the firstposition and the second position. The stacking step can be accomplishedthrough the use of robots, for example.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A method of processing rolls of fibrousmaterials, the method comprising: providing a module comprising aninternal adjustment mechanism; attaching a first piece of equipment tothe module to enable the module to perform a first function; adjustingthe module for the first piece of equipment using the internaladjustment mechanism of the module; removing the first piece ofequipment from the module; attaching a second piece of equipment to themodule to enable the module to perform a second function; and adjustingthe module for the second piece of equipment using the internaladjustment mechanism of the module, wherein the first piece of equipmentis different than the second piece of equipment, and wherein the firstfunction is different than the second function.
 2. The method of claim1, wherein the first piece of equipment comprises more than one piece ofequipment.
 3. The method of claim 1, wherein the second piece ofequipment comprises more than one piece of equipment.
 4. The method ofclaim 1, wherein the first function comprises any of metering, stacking,forming, folding, end sealing, die sealing, manipulating, case forming,case loading, and case closing.
 5. The method of claim 1, wherein thesecond function comprises any of metering, stacking, forming, folding,end sealing, die sealing, manipulating, case forming, case loading, andcase closing.
 6. A method of processing rolls of fibrous materials, themethod comprising: providing a first module and a second module, whereineach module comprises an internal adjustment mechanism; attaching afirst piece of equipment to the first module; adjusting the first pieceof equipment using the internal adjustment mechanism of the first moduleand independent of any adjustment mechanisms on the first piece ofequipment; attaching a second piece of equipment to the second module;and adjusting the second piece of equipment using the internaladjustment mechanism of the second module and independent of anyadjustment mechanisms on the second piece of equipment, wherein thefirst piece of equipment is different than the second piece ofequipment, and wherein the first module is positioned upstream of thesecond module.